Saw chain grinding machine

ABSTRACT

A grinding wheel is mounted on a machine base, and a pair of saw chain holders disposed on opposite sides of the grinding wheel are also mounted on the base. The holders are urged toward the grinding wheel by a spring and are moved away from the grinding wheel by pull cables operated by foot pedals. A turnscrew assembly is rotatably supported on the base and has right and left-hand threads on opposite ends thereof on which are threadedly mounted stop fingers arranged such that by adjustment of one of the stop fingers for selectively locating its respective holder with relation to the grinding wheel, the other stop finger is simultaneously adjusted so that the other holder is positioned in precisely the same spaced position as the first mentioned holder but on the opposite side of the grinding wheel. A releasable solenoid operated holddown lever for the saw chain is provided on each holder, and these levers are released when the foot pedals are depressed, such being accomplished by means of switches in the circuit to the solenoids and arranged for engagement by the foot pedals.

United States Patent 72] Inventor Thomas A. Ribich, Cleveland, Ohio I21) Appl. No. 98,610

I221 Filed Dec. 16,1970

I45 I Patented Nov. 30, 1971 73 Assignee The Weldon Tool Company Continuation-impart of Ser. No. 806,985, Mar. 13, 1969, abandoned [54] METHOD FOR PRODUCING A BALL-END MILL 7 Claims, 31 Drawing Figs.

[52} US. Cl 76/101 R, 51/225,288; 90/1l.42 [51] Int. Cl .B2llr 5/00 [50] Field of Search 76/101 A, 108; 51/288,225

[56] References Cited UNITED STATES PATENTS 2,352,489 6/1944 Melin 51/225UXR 2,902,259 9/1959 Tilden 76/101AUXR 3,365,843 1/1968 Robinson 51/225 Primary Examiner Bernard Stickney A norneys Woodling, Krost, Granger & Rust ABSTRACT: A ball-end end mill is produced by a method and apparatus which performs machining operations on a ball-end end mill blank which blank includes a shank from which extends a plurality of helically extending peripheral teeth which terminate short of the end of the blank which spherical end above themdrizohtal reference plane. The end or the angularly disposed blank is broilght longitudinally into the milling cutter a short distance and then a pivoting action occurs to pivot the blank about an axis parallel to the vertical reference plane through an angle of on the order of the same number of degrees as the helix angle of the peripheral teeth, to arcuately form the cutting face on one tooth and the trailing edge on an adjacent tooth. The blank and cutter are separated, the pivoting action reversed, the blank is indexed about its own axis to bring another portion of the end of the blank into position relative to the cutter, and the above operation is repeated to arcuately: form the cutting face on another tooth arid the t railing edge on another adjacent tooth. This procedure is repeated until all of the teeth are formed. The teeth are finally finish formed by use of another milling cutter of slightly different form by essentially the same operations. A machining operation is next performed on the end of the formed teeth where they all meet at the axis of the tool which involves making an axial cut or notch in all but two diametrically disposed teeth, to separate them slightly from the tool axis. The above operations are accomplished in the unhardened condition of the blank. The blank is then hardened and thereafter ground to form a cutting edge on the two diametrically disposed teeth, each of which extends substantially to the axis of the tool and includes primary and secondary relief surfaces. Cutting edges are also ground on the other teeth and include primary and secondary relief surfaces.

PAT-ENTEUNUV 3019?! 3.624.718

SHEET 01 0F 10 INVENTOR. THOMAS A. RIB/CH PATENTEDNUV 30 I97| 3.624.718

SHEET 62 HF 10 IN VENTOR.

THOMAS A. RIB/CH BY Q i Y M PATENTEBNUV 30 l97| SHEET 03 [1F 10 PATENTEDNUV 30 |97| SHEET UBUF 1O INVEN TOR.

THOMAS A. RIB/CH BY Mr mbudufi PATENTEUNuv 30 I9?! SHEET 07UF 10 PATENTEBNUV 30 l97l 3,624.718

SHEET 03 0F 10 IN VEIV TOR. THOMA .S A. RIB/CH PAIENTEnuuvsoml 3,624,718

SHEET 100F 10 IN VE N TOR.

THOMA S A. RIB/CH 1): M m? M METHOD FOR PRODUCING A BALL-END MILL This application is a continuation-in-part application of Ser. No. 806,985, filed Mar. l3, 1969, now abandoned.

The present invention has as its principal object a method and apparatus whereby ball-end end mills can be mass produced with consistently accurate results. The invention enables one to repeat the geometry of the tool in the ball region and enables one to produce on the joined straight portions of two flutes which go to center, a radial rake angle of substantially zero (for a desired number of degrees on either side of center, for example 15 degrees) so that when the tool FIG. 15 is a view similar to FIG. 13 but showing the blank moved longitudinally into engagement with the cutter a 1 short distance;

FIG. 16 is a view taken generally along the line 16-16 of FIG. 15;

rotated approximately twenty degrees from the position shown in FIG. 16;

FIG. 19 is a view similar to FIGS. 17 and 18 but shows the position of the milling cutter and ball-end end mill blank at the end of the rough milling operation which completes one is resharpened this rake angle can be maintained consistently tooth to the condition of FIG 8;

the same which in turn results in consistent cutting qualities in the tool.

Other objects and a fuller understanding of this invention may be had by referring to the following description and FIG. is an end view of a six-fluted ball-end end mill blank;

FIG. 21 is a view taken generally along the line 21-21 of FIG. 20;

claims, taken in conjunction with the accompanying draw" 20 FIG. 22 is an end view of the ball-end end mill blank shown i s-L wis FIG, 1 is an elevational view of the apparatus of the present invention;

FIG. 2 is a plan view of FIG. 1;

FIG. 3 is a view taken generally along the line 3-3 of FIG. 2;

FIG. 4 is an enlarged view taken generally along the line 4-4 of FIG. 2;

FIG. 5 is a view taken generally along the line 5-5 of FIG. 4;

in FIG. 20 after a first or rough milling operation has been performed thereon;

FIG. 23 is an end view of the ball-end end mill blank shown 5 in FIG. 22 after a further milling operation;

FIG. 6 is an end view of a ball-end end mill blank which is the starting item utilized in the practice of the teachings FIG. 26 is a view taken generally along the line 26-26 of eP s i ve iisn FIG. 7 is an elevational view of the ball-end end milr blank taken generally along the line 7-7 of FIG. 6;

FIG. 25',

FIG. 27 shows the notching operation performed on the blank of FIG. 9 to produce the ball-end end mill of FIGS. 10

FIG. 8 is an end view of the ball-end end mill blank shown and 11;

in FIG. 6 after the rough or first milling operation has been performed on each of the four flutes;

FIG. 9 is an end view of the ball-end end mill blank after the finish or second milling operation has been performed on each of the four flutes;

FIG. 10 is an end view of the ball-end end mill blank after a notching operation has been performed by another milling cutter to complete the end of the ball-end end mill;

FIG. 11 is a view taken generally along the line 11-11 of FIG. 10; r

FIG. 12 is a view taken generally along the line 12-12 of FIG. 11;

FIG. 13 is an elevational view of a first milling cutter and the ball-end end mill blank shown in FIGS. 6 and 7 just prior to engagement of the two to machine one of the teeth to the condition shown in FIG. 8;

FIG. 14 is a view taken generally along the line 14-14 of FIG. 13;

FIG. 28 is a view taken generally along the line 28-28 of FIG. 27;

FIG. 29 is a view similar to FIG. 10 after a final grinding operation to place a cutting edge on the teeth of the four fluted bail-end end mill;

FIG. 30 is an enlarged view of a portion of FIG. 29; and,

FIG. 31 is a view similar to FIG. 24 after a final grinding operation to place a cutting edge on the teeth of the six-fluted ball-end end mill.

The apparatus of the present invention is best seen in FIGS. 1 through 5 of the drawings and is for the purpose of producing ball-end end mills from a ball-end end mill blank which will be described in more detail hereinafter. This apparatus serves to mount both the milling cutters and the ball-end end mill blank and causes the two to be properly moved relative to each other To this end the apparatus includes a base 30 which serves to mount a generally horizontally disposed table 32. The table is carried on ways in a support 34 and this enables the table to be moved back and forth in the directions indicated by arrows 36. The support 34 in turn is carried on a cross slide 38 which enables the support 34 and the table 32 which is carried thereby to be moved back and forth in a direction at right angles to the direction 36. This direction of movement is indicated by the arrows 40 in FIG. 2. The table 32 as well as the support 34 and slide 38 are also adapted to be moved vertically up and down in the direction of arrows 41 by cylinder 53 in the functioning of the apparatus and a fine. vertical adjustment is provided bymeans of the hand crank 42 which actuates a screw 43. The apparatus is also provided with a mechanism for rotating the support 34 and as a result the table 32 carried thereby, about a vertical pivot 44 substantially between the limits of the'full line position shown ini FIG. 2 to the dot-dash position 45 shown in FIG. 2. This includes a hydraulic cylinder 47 mounted as shown in FIGS. 2 and 3.

A vertical support 46 extends from the base for the purpose of rotatively carrying a milling cutter shaft 48. The shaft' 48 is adapted for rotation above the table 32 and as will be seen the axis of the shaft 48 is generally transverse or at right angles to the direction 36 which is one of the directions of movement 25 of the table 32. A first milling cutter 50 or relieving milling cutter is carried by the shaft for rotation therewith and a second milling cutter 52 or flute cutter is also carried by the shaft 48 in precise axially spaced relation to cutter 50. Rotation of the shaft 48 causes rotation of the cutters.

of a set screw 58. A ball-end end mill blank 68 is held within the axial opening in sleeve 57 (after being properly angularly and axially oriented with respect to the sleeve) by means of a threaded member 61 engaging a flat surface portion on the blank 68. An indexing disk 62 is secured to the rear end portion of the housing 56. A detent 65 (FIG. is adapted to reside; in notches in the indexing disk 62 so as to properly angularly locate the housing 56 and as a result the ball-end end rnill .blank 68, with respect to the cutters 50 and 52. It will be seen that these notches are appropriately locatedto accommodate either a four-fluted ball-end end mill blank or a six-fluted ball-end end mill blank. When a four-fluted mill is being machined, the four notches which are located 90 apart are utilized, and when a six-fluted end mill is being machined, the six notches which are located 60 apart are utilized. The work face of a tooth in the ball region of the workpiece. This is necessary because the arc radius varies for different diameter 5 tools.

The back and forth movement of the table 32 in directions E36 and 40 is accomplished by hydraulic cylinders 49 and 51 respectively and vertical movement 41 is caused by hydraulic l cylinder 53. The starting and stopping sequence is controlled by a master cam and appropriate limit switches and stops posil tioned in the path of movement of the various movable parts of 1 the apparatus. This control mechanism has not been described in detail because it is substantially conventional in nature and i ioes not form a part of the present invention.

The method of the present invention will be described in connectio n wi t h the making of both'afour-fluted ball-endend rnill and a six-fluted ball-end end mill. Ihe {gul -fluted ball;end l end mill will be described first and this particular design has lbeen shown and described with a helix angle. It will be appreciated that ball-end end mills having a different helix angle rnjght also be appropriately constructed for examplel gills having a 36 or 4 5 helix angle. A four-fluted ball-end l end mill blank 68 is selected as shown in FIGS. 6 and 7 and l is appropriately secured in the sleeve 57 as shown in FIGS. 1

lthrough 4. The angular position of the blank is appropriately l adjusted as well as its axial position in the sleeve. The table j 32 is then caused to tFavel from the position shown in FIG. 1 I to the left to a position just prior to engagement of the extreme end of the blank 68 with the milling cutter as shown in l FIGS. 13 and 14. The cutter 50 is the first cutter utilized in accomplishing the first or rough machining operation and transforming the blank of FIG. 6 to the initially machined l condition shown in FIG. 8. The table 32 moves the blank 68 straight into the cutter 50 as shown in FIGS. 15 and 16 for the distance shown. The table 32 is then caused to pivot about 3 the pivot 44 which pivot is at a right angle to and intersects g the axis of shaft 48. This causes the blank 68 to move from the position of FIGS. 15 and 16 through the position of FIGS. 17 l and 18 and it stops at the position of FIG. 19. This causes the portion of the blank 68 at the ball end between teeth 70 and :71 to be removed which removed position is indicated by the reference numeral 72 in FIG. 8. This initially forms the cutting face ot tooth 70 and the trailing edge of tooth 71. The milling l cutter 50 and the blank 68 are then separated or brought out of lcontact with each other by vertical lowering of the table 32 1 and returning it to the position of FIG. 1. The indexing disk 62 is next rotated 90 to bring tooth 73 into the previous @position of tooth 70 and to move tooth 70 to the previous position of tooth 71. The same machining procedure is again repeated to initially form the cutting face of tooth 73 and to form the trailing edge of tooth 70. This removed material position is indicated generally by reference numeral 74 in f FIG. 8.Il 1w. ne procedure is again utilized to remove the material identified generally by the reference numerals 76 holder 54 and the associated structure are designed so as to 5 5, and 77 WhiCh s located tw en teeth 71 and vsanzsana locate the axis of the blank 68 at on the order of a 35.angle with respect to the reference plane within which the table 32 lies, which in this particular embodiment is a horizontal reference plane. An angle of on the order of 35 is considered to be substantially ideal for the machining of the geometry on the end of a ball-end end mill in accordance with the present teachings, however, this angle may be varied somewhat within limits. This particular angle has been arrived at because the teeth on the ball end of the mill which are '71, 73 and 75. In this respect, the procedure utilized and the ov e t t l machined blend in extremely well with the continuation of the m cm H S of he b ank relanve to the mlumg cutter 52 are were increased to 45, however, this is not preferred over the.

3 le-s mm The work holder 54 is laterally adjustable in the direction of arrows 40 with respect to the table 32. This is to vary the distance between the pivot 44 and the work holder for the 229 s strainer.ilrarssi silhears 2519199422.. @1211 the same as the movements shown and described in conjunction with FIGS. 13 through 19. In this operation, the configuration of FIG. 9 is formed.

The ball-end end mill blank 68 which is started with is shown in FIGS. 6 and 7 and is provided with a shank64 and M v peripheral teeth extend in a generally helically extending direction and terminate short of the work end of the finished ball end mill. For convenience in identification these peripheral teeth are identified by the reference numerals 70A, 71A, 73A

rotated through, about the vertical pivot 44, to complete" the work end of the finished ball-end end mill and properly arcuately blend into the helical peripheral teeth, is substantially equal to the helix angle of the peripheral teeth. In other words, the angular rotation shown in FIGS. 17, 18 and 19 is substantially 30 which is the helix angle of the peripheral teeth.

FIGS. 27 and 28 show the final machining operation necessary to accomplish the teachings of the present invention. This machining operation produces two notches 83 and 84 in the work end of the ball-end end mill and are for the purpose of the number of degrees of rotation which the biank-imust be H separating the teeth 71 and 73 from the center on the extreme end of the mill. The notches 83 and 84 are produced by holding the partially completed blank of FIG. 9 in the fixture 86 of FIGS. 27 an d 2;8 and then moving the fixtureforwardly so as to bring the end portion of the blank of FIG. 9 into contact with a milling cutter 87 which produces the notch 83. The

blank is then rotated 180 degrees and the notch 84 is produced in a like manner. It should be appreciated that the above referred to machining operations to arrive at the configuration of FIGS. 10 and 11 are performed in the unhardened condition.

The device of FIGS. 10 and 11 is next hardened and thereafter FIGS. 20 through 26 ShOW a six-flutgd ball-end end mill 3 blankil') before and after various machining operations have been performed thereon. The teeth which are machined on the hemispherical end 88 of the blank have been identified by the reference numerals 90 through 95 and the peripheral teeth which are originally provided on the blank 89g; ide r1 t it ig1 by numerals 90A through 95A. The blank is held in a sleeve like 57, however, since this blank is of a different diameter the sleeve must have an opening large enough to accommodatethe blank. The teeth 90A through 95A on the blank 89 extend at a 30 helix angle. The blank 89, as held by the work holder, is brought into contact with the milling cutter which may be of slightly different cutting edge configuration for different diameter end mills and for mills with a differing number of t flutes. The same movement is imparted to the blank, namely 50 that of bringing the blank lognitudinally into contact with the cutter SD -asin FIG. 15 and 16 and then rotating the blank through the positions of FIGS. 17, t8 and 19. The remaining five teeth are machined in the same manner by rotatively indexing the blank by means of the indexing disk 62. detent did, and. the six notches 63 which are spaced sixty degrees apart. This produces a configuration as shown in FIG. 22 and the space where material has been removed from between the teeth is identified by reference numerals 96 through 101. The table 32 is next indexed to bring the blank 89 into position relative to milling cutter 52 to machine the blank to the condition shown in FIG. 23. This accomplished in essentially the same manner as producing the configuration of FIG. 9 from FIG. 8 except that six teeth are involved and except for milling between teeth 96 and 95 and teeth 92 and 93. In these two instances when these portions are in position to be machined by cutter 52 the automatic cycling of the apparatus causes the table to be raised vertically in the direction 41 (by cylinder 53) of on the order of .050 inches greater than normal. This brings these two cuts closer to the center of the ball mill as shown in MG. 23. Notches 104 and 105 are next provided on the apparatus of FIGS. 27 and 23 so as to space or separate teeth 9t, 92, 5M and 95 from center. These machining operations are likewise accomplished in the unhardened condition of the blank which is thereafter hardened. A grinding operationj th n pcri'qtuwd FQPIQWW the communially completed ball-end end mill of FIG. 31

which has cutter edges IE5 and primary and secondary relief surfaces 116 and 117. The cutting edges on teeth and 93 go substantially to center and produce a radial rake angle of substantially zero degrees a short distance on either side of center. FIG. 25 shows, for the sake of example only, the rake angles of the cutting edge at various angular positions on the ball end. FIG. 26 shows the flute contour in the ball region of this ball-end end mill as does FIG. 12 in the case of the ball-end end mill of FIG. 11.

In the event the helix angle of the mill which is being produced is different from the 30 angle as described in the present embodiment, for example, if it were 40, then the table 32 which carries the blank through the positions of FIG. 13 through FIG. 19, would be swung through approximately a 40 angle. If the helix angle were 45 then the angle through which the blank is swung or pivoted would also be approximately 45".

It will be apparent to those skilled in the art after reviewing the hereinabove disclosure that the present apparatus and method are capable of producing ball-end end mills from the hereinabove described blank on a mass production basis and with an accuracy of the geometry on the end of the mill which was not heretofore believed possible. This particular apparatus and method is also capable of producing a completed ball-end end mill wherein the rake angle at center and through a desired angle from center, say for example 15. can be maintained at substantially zero. This is highly advantageous in resharpening these tools after they have once become dull from use. With this particular construction, when resharpened, the rake angle is still maintained at zero and as a result the resharpened tool can be expected to perform and does perform in a manner which is substantially identical with the manner in which it performed when it was new.

While milling cutters have been specifically disclosed above it will be appreciated that other equivalent metal removal means can be utilized for example grinders, particularly for producing tools on the order of 5/8" OD. and

1 The method of making a ball-end end mill from a ballend end mill blank which has a shank from which extend generally helical peripheral teeth which terminate short of an end which is comprised of a substantially hemispherical surface; including the steps of presenting the hemispherical end of the blank to a rotating metal removal means with the axis of the metal removal means being generally parallel to a reference plane, moving the end into contact with the metal removal means with the axis of the blank making an acute angle with the reference plane, pivoting the blank about an axis which is generally normal to the reference plane to produce a cuttingf ce on one tooth to substantially said one end of fhe blank and to prodiice atrailiiigedge on an adjacent tooth to substantially said one end of the blank. separating the metal removal means and blank, indexing the blank about its own axis to successively present different angular portions of the hemispherical end of the blank to the rotating metal removal means and repeating the above operations to complete all of the plurality of teeth to the said one end of the blank.

2. The method of making a ball-end end mill from a ballerid end mill bianl; which has a shank from which extend generally helical peripheral teeth which terminate short of an end which is comprised of a substantially hemispherical surface; including the steps of presenting the hemispherical end of the blank to a rotating milling cutter with the axis of the cutter being generally parallel to a reference plane, moving the end into contact with the cutter with the axis of the blank making an acute angle with the reference plane, pivoting the blank about an axis which is generally normal to the reference plane to produce a cutting face on one tooth to substantially said one end of the blank and to produce a trailing edge on an adjacent tooth to substantially said one end of the blank, separating the cutter and blank, indexing the blank about its own axis to successively present different angular portions of the hemispherical end of the blank to the rotating miller cutter and repeating the above operations to complete all of the plurality of teeth to the said one end of 5, The method of clai n 1 4, wherein the acute angle of the axis of the blank is on the order of 35 degrees.

6. The method of making a ball-end end mill from a ballend end mill blank which has a shank from which extend generally helically extending peripheral teeth which terminate short of an end which is comprised of a substantially hemispherical surface; including the steps of presenting the r alsmi an to fir t. tat n i a ,cutter with the axis of the cutter being generally parallel to a horizontal reference plane, moving said end into contact with the cutter in a straight line direction generally parallel to said horizontal reference plane and normal to the axis of I the milling cutter with the axis of the blank making an acute angle with said horizontal reference plane, pivoting the blank about an axis which is normal to said horizontal reference plane through an angle of on the order of the same number of degrees as the helix angle of the peripheral teeth to form a cutting face on one tooth to substantially said one end of the blank and to form a trailing edge on an adjacent tooth to substantially said one end of the blank, separating the cutter and blank, rotating the blank about its own axis to successively present different angular portions of the hemispherical blank to the first rotating miller cutter and repeating the above operations to form all of the plurality of teeth to the said one end of the blank, presenting the formed teeth to a second rotating milling cutter with the formed teeth oriented in essentially the same manner as oriented to said first rotating miller cutter and moving the blank with respect to said second rotating milling cutter as it was moved with respect to said first rotating milling cutter to finish form the cutting faces on said teeth, and bringing the said one end of the blank generally axially into contact with another milling cutter to terminate each of said teeth from the said one end except two.

7. The method as claimed in claim 6, wherein at least two oppositely disposed teeth are finished formed by said second milling cutter closer to the center line of the blank than the other teeth. 

